Template guidance system for a router

ABSTRACT

Tapered, stepped, or non-tapered router guide templates, optionally combined template holder system, and optional tapered or non-tapered guide bearing on a readily-locatable and lockable shaft, each template comprising: a base portion, a top portion, at least one of an exterior surface interconnecting the base portion and the top portion along an outer periphery of the template and an interior surface interconnecting the base portion and the top portion along an inner periphery of the template, wherein optionally one of the exterior surface and the interior surface may be continuously tapered between the base portion and the top portion, or stepped, and wherein the base portion is adapted for removable and adjustable interconnection with the template holder system.

CROSS-REFERENCE TO RELATED APPLICATION

The present patent application is a continuation-in-part patentapplication filed under 35 U.S.C. § 120 and claiming the priority andbenefit of U.S. patent application Ser. No. 15/650,794, filed 14 Jul.2017.

FIELD OF INVENTION

The present invention relates to a template-guided system for routers,and more particularly to a template-guided system for pantograph-typerouter systems comprising a lockable collar providing easilyadjustable-depth and easily repeatable location of a guide bearing wheelon a shaft, wherein the guide bearing wheel may either comprise atapered guide bearing wheel, or alternatively a not tapered guidebearing wheel, to be used with a readily adjustable template holder anda readily-adjustable template, or readily-adjustable templates, tofacilitate efficient and highly accurate router cuts.

BACKGROUND OF INVENTION

As shown in FIGS. 1A-D, a router 10 (as shown in FIG. 5) has beencommonly used with a pattern or jig 12, 14, 15 to follow a shape or aform. Some jigs have used a bit-mounted guide bearing 16 to follow theshape, and some jigs have used the base of the router, or a collararound the bit, to follow the inside or outside of a pattern. These haveall been one-to-one ratio router guide systems where the pattern 12, 14has been the same size, or has allowed the same travel, as the desiredcarved or cut pattern or shape in the workpiece.

A Hybrid PantoRouter™, PantoRouter™ 49 shown in FIG. 5, and other routersystems, have used a router to make cuts in wood, plastic and softmetals. The bit 52 for such a router 49 typically spins at up to ˜24,000RPM and is often difficult to precisely control using conventional,manually-operated, methods and commonly available jigs and templates.Templates and template holder systems available to date, such as thosefrom JDS Multi-Tools or Rockler Woodworking and Hardware, have beenmanufactured and sold in fixed sizes and shapes and have not allowed thedegree of fine adjustment provided by the present invention tocompensate for slightly different router bit diameters, for example asmay have been encountered from one bit manufacturer to another, to allowfor desired glue space, or to compensate for different wood species. Themanufacturer of the JDS Multi-Tools and Rockler Woodworking and Hardwarejigs have offered different templates of slightly different sizes, butno other system has been provided by the prior art to allow simplemicro-adjustment of a router like that of the present template system.

PantoRouter router systems comprise a guide bearing that is adapted tofollow along a template, and the position of such a guide bearing hasbeen adjustable to varying depths to affect the positioning of the guidebearing relative to a template used to create, for example mortise andtenon, joints for joining wood members together. This adjustment of theguide bearing of the PantoRouter system has been somewhat time-consumingand has required a moderate amount of trial and error to set the depthof the guide bearing to an appropriate depth.

A common method of alignment of a workpiece on a mount or table has beento measure the thickness of the workpiece using a scale or caliper,after which the user, or operator, has moved the router or mount tocenter the desired joint or shape on the workpiece. A common method offitting the joint has been to cut the mortise first then to haveadjusted the size of the tenon for the proper fit. This common methodhas required trial and error to find the desired fit each time a similarjoint has been cut. With these common methods, there have often beenrequired multiple test cuts and fine-tuning before a cut has beenaccurately centered. Of course, a downside of such a system has beenwasted material, uncertainty in the process of cutting, and this hasalso resulted in a final product that has frequently not been as preciseas would otherwise have been desirable. This in turn has led towoodworking joints, for example, such as mortise and tenon, dovetail,and box joints, that have not been as durable and have not been asaccurately-fitting as would otherwise have been desirable. Or, to attainthe same level of precision as the present invention would have takenmuch longer for set-up and multiple test cuts.

Further, while many prior art templates available today have beenfactory-supplied and are of good quality, nevertheless imperfections insuch factory-supplied templates as shown at 18 on FIG. 1C, or incustom-made templates, have been transferred to the cut or carving atfull scale. This in turn has provided a lower quality, less durable, orslower output in design and functionality than would otherwise have beendesirable.

SUMMARY OF THE INVENTION

A PantoRouter™-type system is advantageous over the prior art, since theaforementioned imperfections in a template are minimized by a reductionin scale of cutting movements, and hence such a system enables a cleanerand more precise cut. And a cleaner, more precise cut, results in a morepleasing, accurate, repeatable and durable resulting workpiece joinery.

The invention shown, described and claimed herein addresses the problemsof prior art router template systems, and it contributes to a moreaccurate, efficient, repeatable, pleasing appearance, and faster cut ona workpiece, as well as safer operating environments for operators. Theinvention is preferably used with a pantographic-type router mount witha 2:1 mechanical advantage over the router, and this mechanicaladvantage gives the operator control and precision superior to any othermanually-controlled means of operation.

In accordance with an aspect of the invention, there is provided atapered relationship between a template and a guide bearing forfollowing the template, wherein preferably the templates, or template,are mounted on a moveable template holder system, or armature, mountedon a moveable or stationary carriage, and wherein preferably the guidebearing, for following the template, is located on a pantographic mount.

In accordance with a first embodiment of this aspect of the invention,there is provided a template which is stepped and/or tapered, either onan inside surface, or on an outside surface, or optionally on bothinside and outside surfaces, to allow micro-adjustments to cuts, orcarvings, in the workpiece to allow greater precision, for example as injoining two workpieces together. Thus, the guide bearing can be moved upor down (in or out on) the steps or taper on the template, which createsa larger or smaller cut in the workpiece by the router bit.

Thus, in accordance with a first embodiment of the invention inaccordance with this aspect of the invention, there is provided a routerguide template comprising: a base portion; a top portion; and at leastone of an exterior surface interconnecting the base portion and the topportion along an outer periphery of the template and an interior surfaceinterconnecting the base portion and the top portion along an innerperiphery of the template, wherein the at least one of the exteriorsurface and the interior surface is continuously tapered or steppedbetween the base portion and the top portion, and wherein the baseportion is adapted for removable and adjustable interconnection with atemplate holder. In those templates having an interior surface, theinterior surface may be tapered, not tapered, or stepped, and theinterior surface and the base portion together may form a concave,stadium bowl-shaped interior in the case of a stadium-shaped templatescommon for creating mortise and tenon-type joinery.

The stadium shape is a geometric figure consisting of a rectangle withtop and bottom lengths a, and the ends of which are capped off withsemi-circles of radius r. The area of a stadium is therefore given byA=π r2+2 r a, and the perimeter by p=2 (π r+a). While a stadium-shapedtemplate, with a stadium-shaped outer periphery and a stadium-shapedinner periphery, or stepped inner periphery, is commonly, and evenpreferably employed in mortise and tenon joinery creation, it will beappreciated that other shapes, such as elliptical, circular, square,round, curved, or other shape appropriate to the desired design outcome,whether for joinery or otherwise, may also be employed with the presentinvention without departing from its true scope as claimed. Therefore,where stadium is mainly used herein to describe the shapes of the outerand inner peripheries of templates herein (and stadium may beinterchangeably used with elliptical herein as pertaining to thedrawings), it will be appreciated that elliptical, circular, square, orother basic shapes in accordance with a desired design outcome, whetherfor joinery or otherwise, may also be substituted without limiting theinvention as claimed.

Combining the outside surface (tenon template) together with the insidesurface (mortise template) in a single template allows the operator tocut both mortise and tenon joints using the same setup, unlike prior arttemplates, which have required multiple additional steps (and thereforeincreased errors and time to set up) by an operator to achieve the sameresult.

In an alternative embodiment of this aspect of the invention, furthercomprising both an exterior surface and an interior surface formed byconcave stepped-bowl-like edges and a base portion, where the interiorsurface actually comprises stepped interior surfaces, each surfaceforming in cross section a stadium (to form larger (upper) and smaller(lower) stadiums having partially concentric end portions) in crosssection and having a larger circumference upper interior surfacepreferably at least at ends of the stadium shape thereof, and a smallercircumference lower interior surface also forming an inner stadium incross section. In this embodiment, preferably an intermediate portion(i.e., the longer edges of the stadium bowl-shaped interior) of theinterior surfaces forming the stadium-shaped concave, stepped-bowl-likeedges are preferably the same width for both the upper interior surfaceand the lower interior surface, but there preferably is a step at eachend in the interior portion of this embodiment of the template which isformed in between the two interior surfaces at each end of thestadium-bowl-shaped interior surfaces. This configuration of templateallows the creation of a mortise having a larger or smaller width toallow more or less adjustability of the mortise and tenon joint.

Thus, in accordance with this embodiment and aspect of the invention,there is provided a router guide template, further comprising both anexterior surface and an interior surface, wherein the interior surfacefurther comprises a plurality of stepped interior surfaces, an upperinterior surface generally describing in cross section a stadium, oralternatively an elongated ellipse, having first and second ends and anelongated middle portion and a lower interior surface generallydescribing in cross section a stadium having first and second ends andan elongated middle portion, wherein at least the ends of the lowerinterior surface comprise a smaller circumference surface than at leastthe ends of the upper interior surface such that an intermediate step isformed at least adjacent the ends of and between the upper interiorsurface and the lower interior surface. Further, in this alternativeembodiment, one or more of the stepped interior surfaces may also betapered.

Referring back to the first embodiment described above in accordancewith this aspect of the invention, both the exterior surface and theinterior surface of the router guide template may be continuouslytapered between the base portion and the top portion, and in this caseat least a portion of the exterior continuous surface may becontinuously tapered inwardly from the base portion to the top portion,and further in such a case where the interior surface is also tapered, acorresponding portion of that interior continuous surface may also becontinuously tapered outwardly from the base portion to the top portion.

Preferably, the taper of the router guide template of this aspect of theinvention comprises a continuously-tapered exterior surface. And wherethe interior surface of such a router guide template is also tapered(optionally), it too may be continuously-tapered. Further, thecontinuous tapers may extend around the entire exterior and/or interiorperipheries, respectively, of the template.

It will be appreciated that different bit diameters used in a routerimpact the size of a template to be used. Thus, it is commonlyunderstood by those skilled in the art that to determine template size,the formula for determining the template size for a Tenon=2(TenonWidth+Bit Diameter)−Guide Bearing Diameter, whereas the formula fordetermining the template size for the Mortise=2(Mortise Width−BitDiameter)−Guide Bearing Diameter. Further, it will be appreciated thatthe router guide template tapers preferably comprise a taper of between0.1 degree and 25 degrees to allow for micro-adjustment of cuts andcarvings.

The tapered templates in accordance with this aspect of the invention onthe pantographic mount are precisely calculated but approximately doublethe desired cut so that any imperfection in the template is translatedonly half-scale to the workpiece, and router control requires less(approximately half) the effort, which as described further below issafer and more accurate. Thus, not only are imperfections in a templateminimized to the degree of 2:1 in the final product of the workpiece,but the 2:1 mechanical advantage in the pantograph system furtherfacilitates the ease and safety with which an operator can performcutting and carving operations using such a system. This is in partbecause, in fact, there is even a greater mechanical advantage than 2:1that is achieved with a pantograph-type router system comparing theoperator handle relative to the cutting blade output. Thus, the taperedtemplates provided in accordance with this aspect of the invention serveto facilitate the ease, accuracy and increased safety of routingoperations with their use in connection with a pantograph-type routersystem.

In an alternative embodiment of this aspect of the disclosure, a guidebearing itself can also be tapered to be used as part of a routertemplate guidance system having a combination guide bearing and apreferably non-tapered template, or a tapered template, for use with arouter with a mechanical advantage between the guide bearing and arouter bit to also allow micro-adjusting of the size and location of acut or carve on the workpiece upon moving of the guide bearing relativeto the template and template holder, or the template holder and templaterelative to the guide bearing, to also allow micro-adjusting of the sizeand location of the cut or carve on the workpiece. Thus, in accordancewith this aspect of the invention, there is provided a router templateguidance system having a combination guide bearing and guide templateadapted for use with a router with a mechanical advantage between theguide bearing and a router bit, comprising: a template comprising anupper portion, a lower portion, and at least one exterior surfaceinterconnecting the upper portion and the lower portion, said templatefurther comprising at least one interior surface interconnecting theupper portion and the lower portion of the template; and a guide bearingcomprising an exterior surface having a taper thereon adapted forfollowing in contact with the exterior surface and the interior surfaceof the template.

Preferably in accordance with the combination guide bearing and guidetemplate of this aspect of the invention, the guide bearing is a guidebearing wheel, and the taper of the guide bearing exterior surfacepreferably extends around the entire exterior guide bearing wheel, orroller, surface and is adapted for contact use with the interior andexterior surfaces of the template to guide a router blade for creating atenon on a workpiece corresponding with the interior of the template,and for creating a mortise on another workpiece corresponding with theexterior of the template, the tenon and the mortise being matched insize and location on the workpieces in order to interconnect theworkpieces.

In accordance with an aspect and embodiment of the disclosure, there isprovided a router template guidance system further comprising a guidebearing assembly, the guide bearing assembly comprising a shaft forcarrying the guide bearing, and a collar adapted to be relocatablylockable at varying locations along the shaft, the shaft being releasably and variably locatable relative to the router, the guide bearingassembly thus being easily repeatably relocatable to a pre-set position.

Such guide bearing assembly is adapted to be easily repeatablyrelocatably lockable at varying locations along the shaft, the shaftbeing releasably and variably locatable relative to the router, theguide bearing assembly being easily relocatable to a pre-set position,whether applied to a tapered guide bearing or a non-tapered guidebearing.

In accordance with another aspect and embodiment of the disclosure,there is provided a router template guide bearing assembly adapted foruse with a pantographic router mount frame. The guide bearing assemblyin accordance with this aspect of the disclosure comprises a shafthaving first and second ends; a guide bearing rotatably mounted on afirst end of the shaft; and a annular collar adapted to be relocatablymounted at an intermediate location between the first and second ends onthe shaft, the shaft, and hence the guide bearing wheel, being adaptablefor installation on an arm of the pantographic router mount to enableready adjustability of the shaft and guide bearing relative to atemplate for guiding a user in making cuts and carves with the router.

In accordance with an embodiment of the disclosure, the guide bearing isa guide bearing wheel, and wherein the taper of the guide bearingextends around the entire exterior wheel surface and is adapted forcontact use with the interior and exterior surfaces of the template toguide a router blade for creating a tenon on a workpiece correspondingwith the exterior of the template, and for creating a mortise on anotherworkpiece corresponding with the interior of the template, the tenon andthe mortise being matched in size and location on the workpieces inorder to interconnect the workpieces.

In accordance with another aspect of the invention, there is furtherprovided, in addition to the template system of either of the aspects ofthe invention described above, a template holder in combination with therouter guide template, the template holder having a plurality of supportpost members, preferably two such post members at either end of thecross member (to allow clearance of a router motor in-between the postmembers), and a cross member interconnecting the support post membersand having a plurality of linear keyed slots therein, wherein the baseportion of the template is adapted for removable and adjustableinterconnection with the linear keyed slots of the cross member of thetemplate holder. Thus, in accordance with this aspect of the invention,the tapered templates are able to be mounted adjustably and removably onone or more of the template holder's plurality of keyed slots or tracks.Into one or more of these cross member keyed slots, the inventionprovides that one or more adjustable keyed portions (i.e., an expandedhead or nut on the end of a threaded bolt passing through the baseportion of each template) and alignment guides (i.e., tapered tenons) onthe base portion (i.e., a back portion) of each template may beremoveably and slideably placed and tightened or loosed. This is similarto a keyed tongue and groove type relationship between each template andthe keyed slots of the template holder cross member, to allowsubstantial adjustability of each template on the template holder. Thekeyed portions of each template are thus able to be tightened or loosed,by fixing or loosening, respectively, the keyed portion of each templateas by screwing the threaded post within the template base, to be able tofix, or install, adjust or remove, a template relative to one or more ofthe tracks on the template holder. The readily adjustable taperedtemplates of the foregoing aspects of the invention allow for greaterease of use of the router to accomplish desired, and more accurate, cutson a workpiece.

In accordance with another aspect of the invention, a thickness gaugefor allowing the operator to quickly, accurately and easily center theheight of cuts in a Y-axis on a workpiece is located on the templateholder support post, or cross-member (see FIG. 10 for an axis diagramfor orientation references for this specification). Thus, the operatoris allowed to insert the workpiece, or sample stock of a same thicknessas the workpiece, further allowing the operator to lock the templateholder in place and to automatically center the cut, joint or shape inthe workpiece, in order to properly adjust the desired height of therouter cutting blade relative to the workpiece before beginning cuttingoperations.

The thickness of the workpiece or sample measured by the gauge isdoubled in a 2:1 pantograph system so that imperfections in the surfaceare translated at half-scale to the workpiece, thus improving precisionof cuts and carves on the workpiece.

Thus, in accordance with this aspect of the invention, the templateholder of the router guide template system further comprises a thicknessgauge for use with a 2:1-ratio-type, pantograph-type router system. Thethickness gauge of this aspect of the invention is for enablingcentering cuts and carvings in a Y-axis of a workpiece, the thicknessgauge preferably further comprising a plurality of clamps on one of thecross member or the support posts. The thickness gauge of this aspect ofthe invention is adapted for holding a sample of stock that is the samethickness as the intended workpiece such that the cutting blade of therouter is adapted to be positioned so as to create one or more of amortise and a tenon in a center location of the workpiece and anotherworkpiece.

In accordance with yet another aspect and embodiment of the invention,each tapered template is provided in a plurality of segments, whereinmultiple segments of tapered templates may be mixed, matched, andcombined to form differing shapes and sizes of cuts. Thus, in accordancewith this aspect of the invention, there is provided a router guidetemplate, wherein the template is comprised of a plurality of segmentsof tapered templates. Further, each such segment of tapered templatecomprises a top portion, a base portion, and at least one of an exteriorcontinuously-tapered or stepped surface interconnecting the base portionand the top portion along an outer periphery and an interiorcontinuously-tapered or stepped surface interconnecting the base portionand the top portion along an inner periphery. Still further, each suchsegment of tapered or stepped template further comprises two mating endportions such that the plurality of segments of tapered templates may beremovably and adjustably attached to the template holder in end-to-endfashion. When combined in this manner, the top portions, the baseportions, any exterior continuously-tapered surfaces and interiorcontinuously-tapered surfaces of each segment are mated end-to-end withan end of another segment forming a continuous top portion, a continuousbase portion, and one of an exterior continuously-tapered surface and aninterior continuously-tapered surface between each mated segment. Whenthe entire plurality of segments are thus mated end-to-end together theyform a complete router guide template with a continuous top portion, acontinuous base portion, and at least one of an exteriorcontinuously-tapered or stepped surface, and an interiorcontinuously-tapered, non-tapered, or stepped surface. This aspect ofthe invention further supports and enables greater ease and flexibilityin forming templates to accomplish a wider range of joining, ordecorative, cuts in the workpiece.

In accordance with one or more aspects of the invention provided above,in an embodiment of the invention, there is provided: A pantograph-typewoodworking router guide template and template holder combination,comprising: a template holder comprising a plurality of post membershaving at least one keyed slot defined along and extending at least aportion of the length of each post member and adapted forinterconnection with a pantograph carriage, the template holder furthercomprising at least one cross member adjustably interconnecting theplurality of post members, the template holder cross member furthercomprising means for removeably retaining at least one template, whereinthe template holder further comprises a plurality of clamps foradjustably fixing the cross member relative to the posts; a templatehaving a base portion and a top portion, the template further comprisingexterior and interior continuous surfaces interconnecting the base andtop portions of the template along an outer periphery and an innerperiphery of the template, respectively, the base portion being adaptedfor removable and adjustable interconnection with the cross member ofthe template. The post members of the template holder are typicallyconnected to the carriage of the pantograph with a plurality of bolts.

In accordance with an alternative, embodiment of one or more of theforegoing aspects of the invention, there is provided a pantograph-typewoodworking router guide template and template holder combination,wherein the interior surface and exterior surface further comprises astepped interior surface having a larger circumference upper interiorsurface and a smaller circumference lower interior surface. Thisconfiguration allows the creation of a larger or smaller mortise toallow for adjustment of the tenon in the mortise.

Preferably, in accordance with an embodiment of a pantograph-typewoodworking router guide template and template holder combination,either or both the exterior continuous surface and the interiorcontinuous surface are one of non-tapered, tapered or stepped.

Further, in accordance with another embodiment of a pantograph-typewoodworking router guide template and template holder combination, boththe exterior continuous surface and the interior continuous surface aretapered, wherein the exterior continuous surface is tapered inwardlyfrom the base portion to the top portion, wherein the interiorcontinuous surface is tapered outwardly from the base portion to the topportion, and wherein the taper of each of the continuously-taperedexterior and interior surfaces extends around the entire exterior andinterior peripheries, respectively, of the template.

Preferably, in connection with this pantograph-type woodworking routerguide template and template holder combination embodiment of theinvention in accordance with any of the foregoing aspects of theinvention, each of the exterior continuous surface and the interiorcontinuous surface is continuously tapered or stepped, and preferablythe taper or step of each of the continuously-tapered or steppedexterior and interior surfaces extends around the entire exterior andinterior peripheries, respectively, of the template.

However, as described in connection with interior stepped surfaces abovein connection with another embodiment and aspect of the invention, theinterior of this embodiment and aspect of the invention may be tapered,non-tapered, or preferably it may be stepped at the ends of thetemplate. Thus, in those templates having an interior surface, where theinterior surface may be tapered, non-tapered, or stepped, the interiorsurface and the base portion together may form a concave,stadium-bowl-shaped interior in the case of a stadium-shaped templatecommon for creating mortise and tenon-type joinery. Thus, in this latterembodiment, the interior-concave-stadium-bowl-shaped end portions of theinterior portion of the template are preferably stepped.

And, thus, in the alternative embodiment of this aspect of theinvention, further comprising both an exterior surface and an interiorsurface formed by concave stepped-bowl-like edges and a base portion,where the interior surface actually comprises stepped interior surfaces,each surface forming a stadium (to form larger (upper) and smaller(lower) stadiums having partially concentric end portions) in crosssection and having a larger circumference upper interior surfacepreferably at least at ends of the stadium shape thereof, and a smallercircumference lower interior surface also forming an inner stadium incross section. In this embodiment, preferably an intermediate portion(i.e., the longer edges of the stadium bowl-shaped interior) of theinterior surfaces forming the stadium-shaped concave, stepped-bowl-likeedges are preferably the same width for both the upper interior surfaceand the lower interior surface, but there preferably is a step at eachend in the interior portion of this embodiment of the template which isformed in between the two interior surfaces at each end of thestadium-bowl-shaped interior surfaces. This configuration of templateallows the creation of a mortise having a larger or smaller width toallow more or less adjustability of the mortise and tenon joint. In thisalternative embodiment, one or more of the stepped interior surfaces mayalso be tapered, elliptical, square, round, curved, or other shapeappropriate to the desired design outcome, and whether for joinery cutsor otherwise.

Further, as described previously in accordance with one or morepreviously-described embodiments and aspects of the invention,preferably the opposing exterior and interior continuous surface tapersof this embodiment of the invention may be generally corresponding andopposed to each other, such that an innermost portion of the exteriorand interior continuously-tapered surfaces near the top of the template(as well as near the base of the template and also in-between the topand the base of the template) may generally correspond so as togenerally guide the operator in cutting and carving.

Still further, preferably in connection with this embodiment of theinvention, the cross member interconnecting the support post membersdefines a plurality of linear keyed slots, and wherein the base portionof the template is adapted for removable and adjustable interconnectionwith the linear keyed slots of the cross member of the template holder.

Still further, preferably, in connection with this embodiment of any ofthe foregoing aspects of the invention, the template holder furthercomprises a thickness gauge on a 2:1-ratio-type, pantograph-type routingwoodworking system, for enabling centering cuts and carvings in a Y-axisof a first workpiece, the thickness gauge further comprising a pluralityof clamps on one of the cross member or the support posts and adaptedfor holding a sample of stock that is the same thickness as the intendedworkpiece such that the cutting blade of the router is adapted to bepositioned so as to create one of a mortise and tenon in the center ofthe workpiece and another workpiece.

Further, in accordance with yet another alternative embodiment of theinvention in accordance with any of the foregoing aspects of theinvention, the template is comprised of a plurality of segments oftapered templates, wherein each segment of tapered template comprises atop portion, a base portion, an exterior (optionallycontinuously-tapered) surface interconnecting the base portion and thetop portion along an outer periphery, and an interior (optionallycontinuously-tapered) surface interconnecting the base portion and thetop portion along an inner periphery, and wherein each segment oftemplate further comprises two mating end portions such that theplurality of segments of tapered templates may be removably andadjustably attached to the template holder in end-to-end fashion suchthat the top portions, the base portions, the exterior (optionallycontinuously-tapered) surfaces and the interior (optionallycontinuously-tapered) surfaces of each segment mated with an end toanother segment end forms a continuous top portion, a continuous baseportion, a continuous exterior (optionally continuously-tapered) surfaceand a continuous interior (optionally continuously-tapered) surface, andsuch that when the plurality of segments are mated end-to-end togetherthey form a complete router guide template with a continuous topportion, a continuous base portion, a continuous exterior (optionallycontinuously-tapered) surface, and a continuous interior (optionallycontinuously-tapered) surface.

The tapered-template system in accordance with one or more aspects andembodiments of the invention summarized above addresses the problem ofinaccurate or complicated joinery using a router and fixed-size guidesor templates, thus enabling quicker, more accurate, safer, andeasier-to-make joinery cuts, whether dovetail, mortise and tenon, or boxjoint cuts. No other known system provides similar micro-adjustment asprovided with the tapered templates of the present invention. With sucha system of the present invention, an operator is enabled in adjustingthe depth of the guide bearing on a pantograph-type router, moving it inor out to engage a different portion of a taper on either or both anexterior surface and an interior surface of a template, to enableeasy-to-make and precise joinery cuts.

Further, the tapered-template system in accordance with one or moreaspects and embodiments of the invention summarized above enables usersin easy and quick micro-adjustments to proposed cuts and carves.

Still further, the tapered-template system in accordance with yetanother aspect of the invention enables operators to more quickly andeasily center the thicknes s (Y-axis) of a joint or shape in aworkpiece. Thus, one or more of the foregoing aspects and embodiments ofthe invention helps users to more quickly and accurately center theirwork on an intended workpiece.

With the use of the tapered-template system in accordance with one ormore aspects and/or embodiments of the invention, operators are enabledin greater control over routers using a pantographic or non-pantographicrouter mount, thus making such template-guided routers easier to use andmore accurate.

The tapered template system in accordance with one or more aspects andembodiments of the invention enables operators in installing andchanging templates and template holders, thus facilitating the work ofsetting up, creating, and taking down, a project.

The subject matter of the present disclosure is particularly pointed outand distinctly claimed in the concluding portion of this specification.However, both the organization and method of operation, together withfurther advantages and objects thereof, may best be understood byreference to the following descriptions taken in connection withaccompanying drawings wherein like reference characters refer to likeelements.

BRIEF DESCRIPTION OF THE DRAWINGS

In consideration of the following detailed description of variousembodiments, the disclosure may be more completely understood inconnection with the following drawings.

FIG. 1A is a perspective view of a prior art template for a router;

FIG. 1B is a perspective view of another prior art template for arouter;

FIG. 1C is a plan view of another prior art template for a router;

FIG. 1D is a front view of a router with a prior art guide bearingthereon;

FIG. 2 is a perspective view of an adjustable template holder for atemplate guide system in accordance with an embodiment and aspect of thedisclosure;

FIG. 3A is a perspective view of a tapered template of a template guidesystem in accordance with an embodiment and aspect of the disclosure;

FIG. 3B is a top plan view of a tapered template of a template guidesystem in accordance with an embodiment and aspect of the disclosure;

FIG. 3C is a bottom plan view of a tapered template of a template guidesystem in accordance with an embodiment and aspect of the disclosure;

FIG. 3D is a side elevation view of a tapered template of a templateguide system in accordance with an embodiment and aspect of thedisclosure;

FIG. 3E is a front elevation view of a tapered template of a templateguide system in accordance with an embodiment and aspect of thedisclosure;

FIG. 4A is a partial side elevation view of a tapered template and guidebearing combination system in accordance with an embodiment and aspectof the disclosure;

FIG. 4B is a partial side elevation view of a template and tapered guidebearing system in accordance with an alternate embodiment and aspect ofthe disclosure;

FIG. 5 is a perspective view of a pantograph-type router on a mount,having a standard guide bearing adjustably mounted thereon, and adaptedfor use with, and in combination with, a tapered template system inaccordance with an embodiment and aspect of the disclosure;

FIG. 6A is a top plan view of a tapered, stepped template of a templateguide system in accordance with an alternate embodiment and aspect ofthe disclosure;

FIG. 6B is a front elevation view of the tapered, stepped template ofFIG. 6A;

FIG. 6C is an illustrative front elevation view of the tapered, steppedtemplate of FIGS. 6A and 6B, further showing in partial phantom view howa guide bearing would interface with the tapered, stepped templateduring operation;

FIG. 6D is a front elevation of yet another alternative embodiment of atapered, stepped template;

FIG. 7A is a perspective view of a plural-segment tapered template inaccordance with an alternative embodiment and aspect of the disclosure;

FIG. 7B is a front elevation exploded view of a plural-segment taperedtemplate in accordance with an alternative embodiment and aspect of thedisclosure;

FIG. 8A is a bottom plan view of a base portion of a template adaptedfor vertical orientation on a template holder in accordance with analternative embodiment and aspect of the disclosure;

FIG. 8B is a bottom plan view of another base portion of a templateadapted for angled orientation on a template holder in accordance withan alternative embodiment and aspect of the disclosure;

FIG. 8C is a bottom plan view of yet another base portion of a templateadapted for horizontal orientation on a template holder in accordancewith an alternative embodiment and aspect of the disclosure;

FIG. 9a is a front elevation partial view of part of an alternativeembodiment of a template comprising an exterior stepped portion and aninterior stepped portion (and without showing tapered tenons and keysfor interconnecting to a template holder as per an aspect of thedisclosure);

FIG. 9b is a front elevation partial view of part of another alternativeembodiment of a template comprising an exterior stepped portion and aninterior non-tapered portion (and without showing tapered tenons andkeys for interconnecting to a template holder as per an aspect of thedisclosure);

FIG. 10 is an illustrative perspective view of a tenon joint on aworkpiece and further illustrating reference X, Y, and Z axes referredto in this specification;

FIG. 11 is a perspective view of a guide bearing assembly comprising ashaft, a locking collar, and a non-tapered guide bearing;

FIG. 12 is a side view of the non-tapered guide bearing assembly with alocking collar shown in FIG. 11 but retained in a router mount frame;and

FIG. 13 is a side view of an alternative and tapered guide bearingassembly with a locking collar and retained in an arm, or handle, of arouter frame.

DETAILED DESCRIPTION OF THE INVENTION

Referring specifically to FIGS. 2 and 3A-E, a template holder system 20in accordance with one or more aspects of the disclosure preferablycomprises a plurality of stands, or posts, 22 (preferably there areprovided two such posts), and preferably a single cross member 24interconnecting the two posts. The template holder system 20 may becomprised of a single post 22 and cross member 24, or more posts 22 maybe employed as well, without departing from the true scope and spirit ofthe disclosure as claimed. However, it will be appreciated by thoseskilled in the art that two such posts is preferable from the standpointof simplicity of use, rigidity and sturdiness of the resulting templateguide system 20.

Each of the posts 22 of the template holder system 20 preferably has keyslots, or grooves, 26 therein for facilitating alignment of thecross-member 24 thereon, for facilitating the adjustment of the templateholder for use as described further hereafter for height adjustment, aswell as for attaching the posts with bolts (four bolts for each post) toholes 55 in the router or pantograph mount 58 (FIG. 5).

The cross-member 24 of the template holder system 20 comprisesmeasurement indicia 28 on an upper edge surface 7, and/or lower edgesurface 5, thereon, either inch or metric scale, to assist withcentering, or otherwise locating, a tapered template 30 on the templateholder in order to allow correspondingly-located cuts on workpieces.Indicia 31 may also be provided on the posts 22 as well, in order tofacilitate measurement of the cross member 24 and height guide 27position, as discussed further below, relative to the posts 22.

The cross-member 24 of the template holder system 20 further preferablycomprises three or more horizontal mounting grooves, or keyed slots, 29,made either of plastic or metal, such as aluminum. Each of the templates30, 30′ (as well as other templates described herein) have correspondingtapered tenons, or tapered tongues, 44 to help orient and fix thetemplates in the keyed slots. The taper of each of these orientingtenons 44, 44′ is provided as slightly larger at a base of each tenonthan at a tip of each tenon, as shown in FIG. 3D, so that upon placementand tightening of the template 30, 30′ onto the template holder 24 asfurther described below, the templates are snugly attached fixed in theslots 29 of the template holder.

These tapered tenons 44 may be oriented longitudinally the length of thetemplate 30 as shown in FIG. 3C, the keyed slots 29 are preferablyspaced about ¾ inch, or about 20 mm, apart which provides optimalspacing for the templates 30, 30′ in order to place single or multiple½″, ⅜″, or ¼″ thick mortise and tenon joints in dimensional lumbercommon to North America, such as 2×4, 2×6, 2×8, etc. Further, pairedmortise and tenon joints may be created with a stacked manufacturingconfiguration where two templates are located on the cross member 24.The template holder 20 also accommodates non-tapered, tapered or steppedtemplates, as further described herein in accordance with one or moreaspects of the disclosure, to make fixed or variably-spaced dovetail andbox joints. The tapered templates 30 may be tapered on the exterior andinterior surfaces to allow micro-adjustment of the joinery.

The template holder 20 further comprises an L-shaped side angle system19 mounted, as with screws to each side of the template holder crossmember 24, and the template holder cross member is partially retainedwithin, and maintained squared relative to, the two L-shaped side anglesby an outer vertically-oriented lip 11 on each L-shaped angle andengaging either end of the cross member. The L-shaped angle system 19,comprises left and right such L-shaped angles on either side of thetemplate holder cross member. The L-shaped angles 19 and cross member24, are removably fixed together with tightening screws so that theL-shaped angles and cross member combination is fixed together andadjustable as a unit, and alternatively able to be fixed, or locked at acertain height, relative to the posts 22 with the use of clamps 21, eachclamp having a tightening lever 23.

The angles 19 and cross member 24 combination are able to be adjusted toan appropriate height according to indicia 31 on one of the posts 22,the workpiece used temporarily for a height measurement as furtherdescribed below, or a representative sample workpiece of the samethickness as the workpiece. Thus, the system of clamps 21 each have atightening lever 23 for the operator to actuate to adjust the templateholder cross member 24 position relative to the posts 22, the pantographcarriage 58, and thus the workpiece, via the L-shaped angles 19 fixed tothe template holder cross member.

Thus, there is also provided a height measurement clamp, or thicknessgauge, 27 for holding a reference, or sample, workpiece/stock 3, toallow simple adjustment of the height of the cross member 24 andattached template 30 relative to the cross member, the routing table 58,and thus the actual workpiece on which cutting or carving is to beperformed. The thickness gauge 27 allows the operator to quickly,accurately and easily center a cut or carving in the Y-axis of an actualworkpiece (see FIG. 10 for an axis diagram for proper orientation forthis specification).

This is accomplished by first referencing the upper surface of thethickness gauge 27 at the cutting table surface, and then by adding thesample/workpiece stock 3, followed by moving the cross member 24 (viathe L-shaped angles sliding along the posts 22) down so that anunderside of the cross member 24 comes to rest on the upper surface ofthe reference stock 3. Thereafter, the operator is able to fix the crossmember 24 at that location using the levers 23 of clamps 21 which thusclamp the L-shaped angles 19 and attached cross member 24 to the posts22 at the desired height. The thickness gauge 27 is built into thetemplate holder system 20, preferably mounted on a template holdersupport post 22, or cross member 24. Thus the thickness of the workpieceor sample is measured by the gauge 27 to accurately position or centerthe joinery on the workpiece.

The clamps 21 are both for adjusting the template holder 20 andoperating the cross member 24 and L-shaped angles 19 combinationrelative to the thickness gauge 27. The thickness gauge 27 is attached,and independently slides into, and is held in place within, the grooves26 in the posts 22, via a screw 27 a. The side angle assembly 19 must bealigned on entry into the groove 26 in the posts 22, and upon tighteningof the clamp 21 via the lever 23. Therefore a part of the disclosureoffsets the clamps 21 so one may be aligned at a time. This makeschanging template holders 20 easier and faster. Thus the template holderand system 20, 21, 22, 24, 27, 30, 54, as well as inventive parts,combinations and other embodiments thereof, enables operators to morequickly and easily center the thickness (Y-axis) of a joint or shape ina workpiece. Thus, this aspect, or these aspects, of the disclosurehelps users to more quickly and accurately center their work on anintended workpiece and allows for greater precision in cuts and carves.

Referring more specifically now to FIGS. 3A-E, there is provided one ormore tapered templates 30 (other embodiments, including non-taperedtemplates, stepped templates, segmented templates, and other types oftemplates, are discussed hereafter in connection with other figures).Each tapered template 30 comprises a top portion 31, a base portion 33,and one or more continuously-tapered surfaces, exterior, outercontinuously-tapered surface 32 a, and interior, innercontinuously-tapered surface 32 b, interconnecting the top portion andthe base portion of each tapered template 30. Each continuously-taperedsurface 32 a, 32 b is continuously tapered in the sense that the surfacehas a continuous taper from the base portion 33 to the top portion 31.In the case of exterior continuously-tapered surface 32 a, the taperpreferably extends continuously inwardly from the intersecting edge 37of the base portion 33 and the tapered surface 32 a to the intersectingedge 39 of the top portion 31 and the tapered surface 32 a. Similarly,in the case of interior continuously-tapered surface 32 b, the taperpreferably extends continuously outwardly from the intersecting edge 41of the interior continuously-tapered surface 32 b and the base portion33 to the intersecting edge 43 of the interior continuously-taperedsurface 32 b and the top portion 31.

In this way, there is provided the ability for micro-adjustment of cutsand carves because of the fact that, to the degree there are providedtapered surfaces, they are adapted to interface in acontinuously-tapered fashion with an adjustable guide bearing 54 (FIGS.4a and 5) to allow for such continuously-adjustable micro-adjustment.

It will be appreciated by those skilled in the art that the templatesdescribed herein may be stadium-shaped, elliptical-shaped or some othershape as shown or described. The terms stadium and elliptical are usedsomewhat interchangeably herein when describing one or more of thefigures. The stadium shape is a geometric figure consisting of arectangle with top and bottom lengths a, and the ends of which arecapped off with semi-circles of radius r. The area of a stadium istherefore given by A=itr2+2ra, and the perimeter by p=2(nr+a). While astadium-shaped template, with a stadium-shaped outer periphery and astadium-shaped inner periphery, or stepped inner periphery, is commonly,and even preferably employed in mortise and tenon joinery creation, itwill be appreciated that other shapes, such as elliptical, circular,square, round, curved, or other shape appropriate to the desired designoutcome, whether for joinery or otherwise, may also be employed with thepresent disclosure without departing from its true scope as claimed.Therefore, where stadium is mainly used herein to describe the shapes ofthe outer and inner peripheries of templates herein (and stadium may beinterchangeably used with elliptical herein as pertaining to thedrawings), it will be appreciated that elliptical, circular, square, orother basic shapes in accordance with a desired design outcome, whetherfor joinery or otherwise, may also be substituted without limiting thedisclosure as claimed.

Each tapered template 30 is provided with a series of holes 45 adaptedfor receiving the key system 42 for use in releasably securing eachtemplate to the cross member 24 slot 29. The key system 42 furthercomprises a machine screw 47 preferably having an allen-wrench or screwdriver slot(s) operable head 49 thereon. In this way, each taperedtemplate 30 is adapted for interchangeable interconnection with a slot29 of the cross member 24.

Each tapered template 30 is held on the slots 29 of the cross member 24of the template holder 20 with the use of a releasably tightenable andadjustable key 42 and tapered tenon 44 system associated with eachtapered template 30 as shown in FIG. 3E. The releasably tightenable andadjustable key 42 and tapered tenon 44 system may employ the use ofmultiple keys 42 as shown in FIG. 3E, or a single key 42′ as shown inFIGS. 6 B-D. In either case, the tapered tenons 44, together with thekey 42, serve to hold the tapered template 30 in aligned position on,and relative to, the template guide system cross member 24.

Referring now specifically to FIGS. 7A-B and 8A, in accordance withanother embodiment and aspect of the disclosure, there are provided aplurality of segments 72, 74, 76 comprising together a tapered template30′. It will be appreciated that other types of templates, whethertapered, non-tapered, stepped, angular, or otherwise as discussed inother locations or in connection with other Figures in thisspecification, may be segmented and/or attached horizontally,vertically, or in angled orientation, to cross member 24 in accordancewith an aspect and embodiments of the disclosure, without departing fromthe scope of the disclosure as claimed.

As with tapered template 30, tapered template 30′, when considered withmultiple segments fit together end-to-end, also comprises a continuoustop portion 31′, a continuous base portion 33′, and one or morecontinuously-tapered surfaces, such as exterior, outercontinuously-tapered surface 32 a′, and/or interior, innercontinuously-tapered surface 32 b′, interconnecting the top portion andthe base portion of each tapered template 30′. Each continuously-taperedsurface 32 a′/32 b′ is continuously tapered in the sense that thesurface has a continuous taper from the base portion 33′ to the topportion 31′. In the case of exterior continuously-tapered surface 32 a′,the taper preferably extends continuously inwardly from the intersectingedge 37′ of the base portion 33′ and the tapered surface 32 a′ to theintersecting edge 39′ of the top portion 31′ and the tapered surface 32a′. Similarly, in the case of interior continuously-tapered surface 32b′, the taper preferably extends continuously outwardly from theintersecting edge 41′ of the interior continuously-tapered surface 32 b′and the base portion 33′ to the intersecting edge 43′ of the interiorcontinuously-tapered surface 32 b′ and the top portion 31′.

In this way, there is provided a tapered relationship not only betweenthe exterior continuously-tapered surface 32 a′ and the interiorcontinuously-tapered surface 32 b′, but there is also provided formicro-adjustment of cuts and carves because of the fact that thesetapered surfaces are adapted to interface in a continuously-taperedfashion with an adjustable guide bearing 54 to allow for suchcontinuously-adjustable micro-adjustment.

In FIGS. 7A-B, tapered template 30′ differs from tapered template 30 inthat tapered template 30′ is comprised of a plurality of segments 72,74, 76. Thus, each of the segments 72, 74, 76 has a top portion 31′, abase portion 33′, an exterior continuously-tapered surface 32 a′, aninterior continuously-tapered surface 32 b′, and preferably a hole 45′,tapered tenons 44′, and key members 42′. Further, each tapered templatesegment 72, 74, 76 also preferably has at least one cross-section endcut 78, and in some cases (i.e., segment 74) a plurality ofcross-section end cuts. Preferably, these cross-section end cuts 78 willmatch corresponding cross-section end cuts 78, so that two or moresegments may be located end-to-end in the slots 29 of cross member 24(as shown in dotted lines at 30′ on FIG. 2) in order to form a completetemplate 30′.

Thus, it will be appreciated that segments 72, 74, 76, or other segmentshaving differing shapes in order to form desired cuts on a workpiece aswill be appreciated by those skilled in the art, may be mixed, matched,and combined to form differing shapes and sizes of cuts. Thus, there isprovided a router guide template 31′, wherein the template is comprisedof a plurality of segments of tapered templates 72, 74, 76. Further,each such segment 72, 74, 76 of tapered template 30′ comprises a topportion 31′, a base portion 33′, and at least one of an exteriorcontinuously-tapered surface 32 a′ interconnecting the base portion andthe top portion along an outer periphery and an interiorcontinuously-tapered surface 32 b′ interconnecting the base portion andthe top portion along an inner periphery.

Still further, each such segment 72, 74, 76 of tapered template 30′further comprises two mating end portions 78 such that the plurality ofsegments of tapered templates may be removably and adjustably attachedto the template holder 24 in end-to-end fashion. When combined in thismanner, the top portions 31′, the base portions 33′, any exteriorcontinuously-tapered surfaces 32 a′ and interior continuously-taperedsurfaces 32 b′ of each segment 72, 74, 76 are mated end-to-end with anend 78 of another segment forming a continuous top portion 31′, acontinuous base portion 33′, and one of an exterior continuously-taperedsurface 32 a′ and an interior continuously-tapered surface 32 b′ betweeneach mated segment.

When the entire plurality of segments 72, 74, 76 are thus matedend-to-end together they form a complete router guide template 30′ witha continuous top portion 31′, a continuous base portion 33′, and atleast one of an exterior continuously-tapered surface, 32 a′, aninterior continuously-tapered surface 32 b′, and even a non-taperedinterior or exterior surface (e.g., for example if template 81 or 83 ofFIG. 8 were to be shown as segmented, since there are not shown guidesurface tapers on these templates). This aspect of the disclosurefurther supports and enables greater ease and flexibility in formingtemplates 30′ to accomplish a wider range of joining, or decorative,cuts in a workpiece.

Each tapered template 30 (30′, 30″, 30′″, 80, 81, 83, 90, 92, etc.) isprovided with a series of holes 45 adapted for receiving the key system42 for use in releasably securing each template to the cross member 24slot 29. The key system 42 further comprises a threaded post 47preferably with an allen-wrench (other screwdriver) operable head 49thereon. In this way, each template is adapted for interchangeableinterconnection with a slot 29 of the cross member 24.

It will be appreciated that any taper of the interior and the exteriortapered surfaces of the templates (e.g., 30) described herein, maybeneficially extend along the entire tapered surface (depending upon thedesired output of such a guided pantorouter system), both from the baseportion (e.g., 33) of the template to the top portion (e.g., 31) of thetemplate, as well as around the entire length, or circumference in thecase of an entirely stadium, elliptical, circular or oval template.Thus, there may be advantageously provided such a taper both near thetop portion (e.g., 31) of the template (e.g., 30), near the base portion(e.g., 33) of the template, in between these two extreme locations, andalong the entire tapered length of the template.

Referring now to FIGS. 6A-D, there is provided an alternative embodimenttemplate 30″, comprised of a stepped, tapered template 30″, wherein,similar to tapered template 30, there is provided a top portion 31″, abase portion 33″, an exterior continuously-tapered surface 32 a″, andstepped interior surfaces 32 b″ and 32 c. Further, as with template 30,and 30′, template 30″ also comprises alignment tapered tenons 44″, and akey system 42″, except unlike the key systems 42, 42′ of templates 30,30′, respectively, template 30″ only has a single key system 42″, whichtogether with the alignment tapered tenons 44″, serves to releasablyhold the template 30″ on a cross member 24 slot 29.

In FIG. 6D, there is provided yet another alternative embodimenttemplate 30′″, comprised of a stepped, tapered template 30′″, whereinsimilar to tapered template 30″, there is provided a top portion 31′″, abase portion 33′″, an exterior continuously-tapered surface 32 a′″, andstepped interior surfaces 32 b′″ and 32 c′. However, unlike taperedtemplate 30″, interior surfaces 32 b′″ and 32 c′ are tapered at each ofthe steps. Like tapered template 30″, tapered template 30′″ alsocomprises alignment tapered tenons 44′″, and a key system 42′″ forreleasably holding the template 30′″ on a cross member 24 slot 29.

Referring now to FIGS. 8A, 8B, and 8C, there are provided alternativetemplates 80, 81, 83, respectively. Each such template has a key system82 similar to that of tapered template 30, for example, and taperedtenons 84, 88, 85, respectively as to FIGS. 8A, 8B, 8C. Because of theorientation of the tapered tenons 84, the segmented template 80 wouldsit vertically on the cross member 24 similar to segmented template 80shown in dotted lines on FIG. 2, whereas the template 81 would sit at anangle on the cross member 24, and the template 85 would sit horizontallyon the cross member 24.

Referring now also to FIGS. 4a and 5, the invention uses a router motor50 (as part of a PantoRouter™, or Hybrid PantoRouter™, router system49), having a router bit 52 and guide bearing, or guide wheel, 54 heldon a guide bearing shaft 83″ on a pantographic mount 56 on a base orcarriage 58. On the pantographic mount 56, the center of the guidebearing 54 is located twice the distance from the reference pivot as thecenter of the router bit 52. The guide bearing 54 is guided by theoperator around or within a template 30, 30′, 30″, 30′″, 80, 81, 83, 90,92 moveably located in the moveable tapered template holder system 20.Using the handle 51 and arm 53 of the pantographic mount 56, theoperator can move the guide bearing 54 up or down the tapers 32 a, 32 bof the tapered template 30, or tapers 32 a′, 32 b′ of the taperedtemplate 31′, etc., which creates a larger or smaller cut in theworkpiece by the router bit 52. In this way, and by adjusting the depthof the guide bearing 54 on a taper on a template via guide bearingadjustment knob 81, the operator is allowed in micro-adjusting the sizeof the cut or carve on a workpiece.

Of course, it will be appreciated by those skilled in the art thattemplates such as those shown in FIGS. 9a and 9b may be adapted for usewith all other aspects of the disclosure, since these templates may beadapted in accordance with this disclosure to include tapered tenons andkeys for interconnecting to a template holder as per an embodiment andaspect of the disclosure. Thus, the template 90 shows an alternativeembodiment of a template comprising an exterior stepped portion and aninterior stepped portion (without showing, for purposes of avoidingredundancy, tapered tenons and keys for interconnecting to a templateholder as per an embodiment and aspect of the disclosure). Moreover, thetemplate 92 shows a template comprising an exterior stepped portion andan interior non-tapered portion (again without showing, for purposes ofavoiding redundancy, tapered tenons and keys for interconnecting to atemplate holder as per an embodiment and aspect of the disclosure).

In accordance with an alternative embodiment of the disclosure as shownadditionally in FIG. 4B, guide bearings can also be tapered as shown at54′ to be used with stepped templates (e.g., 30″ of FIG. 6B, or 90 ofFIG. 9A), non-tapered templates 30″″, tapered templates (e.g., 30 ofFIGS. 3A-E), or segmented templates (e.g., 30′ of FIGS. 7A-B and 80 ofFIGS. 8A and 2), to also allow micro-adjusting the size of the cut orcarve on a workpiece.

The disclosure, or certain aspects thereof, can be used in any position,including but not limited to horizontal, such as with a HybridPantoRouter™ and PantoRouter™, or vertical such as a pin router orsimilar application. The disclosure, or certain aspects thereof, canalso be used with non-pantographic router mount devices. Thus, thetemplate holder system in accordance with an aspect of the disclosurecan be moved to different positions, different jigs, or with differentmachines.

The tapered-template system in accordance with an aspect of thedisclosure addresses problems of safety, inaccurate joinery using arouter and fixed-size guides or templates. Thus, the disclosure enablesquick, accurate, safer and easy-to-make joinery cuts, whether dovetail,mortise and tenon, or box joint cuts.

Further, the tapered-template system in accordance with an aspect of thedisclosure allows for easy and quick micro-adjustments to cuts andcarves, and thus certain aspects of the disclosure enable quick,accurate and easy-to-make micro-adjustments to a proposed cut. With theuse of the template system (whether with non-tapered, tapered, orstepped templates) in accordance with one or more aspects of thedisclosure, operators are enabled in greater control over routers usinga pantographic router mount in order to make routers safer, easier touse and more accurate. The tapered template system in accordance with anaspect of the disclosure enables installing and changing templates andtemplate holders, thus facilitating the work of setting up, creating,and taking down, a project.

As shown in FIG. 11, there is provided a guide bearing assembly 1100comprising a shaft 1102, a locking, or lockable, collar 1104, the collarhaving a tightenable screw 1106 for allow adjustability of the collar onthe shaft. The guide bearing assembly further comprises a bearing wheel1108, which in the embodiment shown is a non-tapered guide bearing wheeladaptable for use as described elsewhere in the disclosure, for example,with a tapered template 30.

The guide bearing assembly 1100 differs from the guide bearing 54 andshaft 83 shown in FIG. 5, in that the guide bearing assembly 1100comprises the collar 1104 added which enables easy positioning(location), and repositioning (relocation) of the shaft 1102, and hencethe guide bearing assembly 1100, relative to arm 53 of the Pantrographicrouter mount 56.

As shown in FIG. 12, there is provided the non-tapered guide bearingassembly 1100 with a locking collar 1104 and on shaft 1102, similar tothat shown in FIG. 11, but in FIG. 12 the guide bearing assembly isshown installed on arm 53 of the pantographic router mount 56, whereinthe pantographic router mount is part of a pantograph router system witha mechanical advantage, e.g., a 2:1 ratio, in the relative sizes of thetemplate and the cutting path, between the guide bearing 54 and therouter bit 52. The shaft 1102 of the guide bearing assembly 1100 is heldin place with a knob 1202 retained on a threaded shaft and screwed intothe arm 53.

To adjust the depth of the guide bearing assembly 1100, one may unscrewthe knob 1202 to loosen its hold on the guide bearing assembly shaft1102 so that the shaft may be either moved closer to the template 30, orfurther away from the template. It will be appreciated that in order tomove the shaft 1102, and hence the wheel 1108, further away from thetemplate, one would have to loosen the screw 1106 on the locking collar1104 to allow the collar to slide along the shaft. Then, once thedesired depth of the shaft 1102 and wheel 1108 has been achievedrelative to the template 30, the collar 1104 may be re-tightened againstthe arm 53 in such a way that the desired depth may be retained uponremoval, and reinstallation, of the guide bearing assembly 1100 into thearm 53.

As shown in FIG. 13, there is provided an alternative, tapered, guidebearing assembly 1300 with a locking collar 1104 and on a shaft 1102,similar to that shown in FIG. 12, with the guide bearing assembly showninstalled on arm 53 of the pantographic router mount 56, the shaft 1102of the guide bearing assembly 1300 also being held in place with theknob 1202 retained on a threaded shaft and screwed into the arm 53.

The tapered guide bearing assembly 1300 is similar to that shown in FIG.4B for use, for example, with a non-tapered template 30′″ (but stillallowing micro-adjustability of depth of cut according to the desireddepth of the guide bearing wheel 1108′, but in FIG. 13 the guide bearingassembly 1300 is shown installed on arm 53 of the pantographic routermount 56, with a locking collar 1104 on shaft 1102 to help locate andhold the guide bearing assembly 1300 at a desired depth relative to thearm 53. Like that shown in FIG. 4B, the guide bearing wheel 1108′ istapered.

To adjust the depth of the guide bearing assemblies 1100, 1300, one mayunscrew the knob 1202 to loosen its hold on the guide bearing assemblyshaft 1102 so that the shaft may be either moved closer to the template30, 30′″, or further away from the template. It will be appreciated thatin order to move the shaft 1102, and hence the wheel 1108, 1108′,further away from the template, one would have to loosen the screw 1106on the locking collar 1104 to allow the collar to slide along the shaft.Then, once the desired depth of the shaft 1102 and wheel 1108, 1108′ hasbeen achieved relative to the template 30, 30′″, the collar 1104 may bere-tightened against the arm 53 in such a way that the desired depth maybe retained upon removal, and to facilitate easily repeatablereinstallation, of the guide bearing assembly 1100 into the arm 53.

In this way, with the use of guide bearing assemblies 1100, 1300,repeated manufacture of, for example, consistently-sized mortise andtenon joints, becomes much easier and much less time consuming. This inturn, prevents wasted materials as well otherwise involved where a moretrial-and-error type method of determining position for the guidebearing wheel 54 relative to a template 30 or 30′″.

Many modifications and other embodiments of the invention set forthherein will come to mind to one skilled in the art to which thisinvention pertains and having the benefit of the teaching presented inthe foregoing descriptions and the associated drawings. Therefore, itshould be understood that the inventions are not to be limited to thespecific embodiments disclose and that modifications and otherembodiments are intended to be included within the scope of the appendedclaims.

I claim:
 1. A router template guidance system having a combination guidebearing and guide template adapted for use with a router with amechanical advantage between the guide bearing and a router bit,comprising: a template comprising an upper portion, a lower portion, andat least one exterior surface interconnecting the upper portion and thelower portion, said template further comprising at least one interiorsurface interconnecting the upper portion and the lower portion of saidtemplate; and a guide bearing comprising an exterior surface having ataper thereon adapted for following in contact with the exterior surfaceand the interior surface of said template, and adapted to enableadjusting the depth of the guide on the exterior surface and theinterior surface of said template for adjustments to the size of cutsand carves.
 2. The router template guidance system of claim 1, whereinsaid guide bearing is a guide bearing wheel, and wherein the taper ofsaid pantograph guide bearing extends around the entire exterior wheelsurface and is adapted for contact use with the interior and exteriorsurfaces of said template to guide a router blade for creating a tenonon a workpiece corresponding with the exterior of the template, and forcreating a mortise on another workpiece corresponding with the interiorof said template, the tenon and the mortise being matched in size andlocation on the workpieces in order to interconnect the workpieces. 3.The pantograph router template guidance system of claim 1, furthercomprising a guide bearing assembly, said guide bearing assemblycomprising a shaft for carrying said guide bearing and a collar adaptedto be relocatably lockable at varying locations along said shaft, saidshaft being releasably and variably locatable relative to the router,said guide bearing assembly being easily relocatable to a pre-setposition.
 4. The pantograph router template guidance system of claim 2,further comprising a guide bearing assembly, said guide bearing assemblycomprising a shaft for carrying said guide bearing and a collar adaptedto be relocatably lockable at varying locations along said shaft, saidshaft being releasably and variably locatable relative to the router,said guide bearing assembly being easily relocatable to a pre-setposition.
 5. A router template guide bearing assembly adapted for usewith a pantographic router mount frame, comprising: a shaft having firstand second ends; a guide bearing rotatably mounted on a first end ofsaid shaft; and a annular collar adapted to be relocatably mounted at anintermediate location between the first and second ends on said shaft,said shaft, and hence said guide bearing wheel, being adaptable forinstallation on an arm of the pantographic router mount to enable readyadjustability and repeatable locatability of the shaft and guide bearingrelative to a template for guiding a user in making cuts and carves withthe router.
 6. The router guide bearing assembly of claim 5, whereinsaid guide bearing is a guide bearing wheel, and wherein the taper ofsaid guide bearing extends around the entire exterior wheel surface andis adapted for contact use with the interior and exterior surfaces ofsaid template to guide a router blade for creating a tenon on aworkpiece corresponding with the exterior of the template, and forcreating a mortise on another workpiece corresponding with the interiorof said template, the tenon and the mortise being matched in size andlocation on the workpieces in order to interconnect the workpieces.